Advantages of the ForceMate2 Bushing Method for Composite Component Manufacture or Repair Applications

Composite structures require holes to be machined for different attachment requirements.  Liners or bushings can be used to protect the holes and provide wear surfaces in joints.  ForceMate2 is a double bushing system that is radially expanded into the composite hole.  The ForceMate2 process provides advantages for repair as compared to a single bushing or liner.

Three rework options will be discussed:

1)      Inner bushing is worn out or ovalized – exchange of inner bushing only

2)      Inner bushing badly damaged and outer bushing affected – repair outer bushing without removal and exchange inner bushing

3)      Collateral damage on both bushings – repair composite with ream to oversize hole and exchange both bushings

The ForceMate2 system installs a bushing interference fit into the composite material and then draws an inner bushing into the hole in a single operation.  The bushings can resist migration and axial movement without staking or bonding, though they can be installed with sealants or coatings if required for the application.  In addition, the process has been tailored so that the inner bushing will move before the outer bushing to protect the composite material.  The bushings are adapted to meet the customer’s unique needs.  The expanded bushing process has been shown to achieve higher retention performance than shrink fit type bushing installations.  Additional benefits of the ForceMate2 system besides the rework options include the use of flanges on both sides of hole, ability to install in areas of access restriction and the use of different materials for the two installed bushings.